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46-1
Front brakes
servicing
Front brakes,
servicing (VW II
caliper)
WARNING!
Do not re-use
fasteners that a
worn or
deformed in
normal use.
Some fasteners
are designed to
be used only
once, and are
unreliable and
may fail if used a
second time. Th
includes, but is
not limited to,
nuts, bolts,
washers, circlips
and cotter pins.
Always follow
recommendation
in this manual-
replace these
fasteners with
new parts where
indicated, and
any other time it
is deemed
necessary by
inspection.
CAUTION!
After installing
brake pads, depre
the brake pedal
firmly several time
to seat the pads in
their normal
operating position
Front brakes, servicing Page 2 / 38
46-2
Note:
Wheel bolt
tightening
torque: 110
Nm (81 ft
lb).
Do not
reuse used
brake fluid.
1 - 10 Nm
(7 ft lb)
2 - ABS
wheel
speed
sensor
Before
inserting
sensor,
clean
fitting hole
inner
surface
and coat
with
lubricating
paste G
000 650
3 - ABS
wheel
speed
sensor
rotor
4 - Wheel
hub
Pressing
in and
out:
Plus
suspension
Page
40-29
Base
Front brakes, servicing Page 3 / 38
suspension
Page
40-1
5 - Screw
6 - Splash
shield
7 - Brake
disc
Thickness:
12 mm
(0.472 in.)
Wear
limit:
10
mm
(0.394
in.)
When
worn
always
replace
both
front
discs
Use
penetrating
oil to
loosen
discs from
wheel hub
if
necessary;
do not use
force to
remove
discs
Front brakes, servicing Page 4 / 38
46-3
8 - Wheel
bolt
9 - 10 Nm (7
ft lb)
10 - Brake
pads
For
vehicles
m.y.
from
1996
(T)
Thickness:
14 mm
(0.551 in.)
Wear
limit: 7
mm
(0.276
in.)
Checking
thickness
Repair
Manual,
Maintenance
Pad
with
larger
friction
area
installed
on
outside
Always
replace
both
pairs at
the
same
time
Removing
and
Front brakes, servicing Page 5 / 38
installing
Page
46-9
11 - Brake
caliper
For
vehicles
m.y.
from
1996
(T)
Removing
and
installing
Page
46-9
CAUTION!
Do not
disconnect
the brake
hose from
the caliper
when
replacing
brake pads.
Do not allow
the caliper
to hang by
the brake
hose. The
unsupported
weight can
stretch and
damage the
hose.
Front brakes, servicing Page 6 / 38
46-4
12 Air
- deflector
plate
13 - Socket-
head
bolt,
lower
25
Nm
(18 ft
lb)
14 - Socket-
head
bolt,
upper
25
Nm
(18 ft
lb)
15 - Lower
spacer
sleeve
16 - Upper
spacer
sleeve
17 - Lower
sleeve
18 - Upper
sleeve
19 - Lower
bushing
20 - Upper
bushing
21 - Brake
caliper
For
vehicles
up to
m.y.
1995
(S)
Front brakes, servicing Page 7 / 38
Removing
and
installing
Page
46-6
Front brakes, servicing Page 8 / 38
46-5
22 - Brake
pads
For
vehicles
up to
m.y.
1995
(S)
Thickness:
14 mm
(0.551 in.)
Wear
limit:
7 mm
(0.276
in.)
Checking
thickness:
Repair
Manual,
Maintenance
Pad
with
larger
friction
area
installed
on
outside
Always
replace
both
sides
Removing
and
installing
Page
46-6
23 Brake
- pad
retaining
spring
Front brakes, servicing Page 9 / 38
For
vehicles
up to
m.y.
1995
(S)
Mount in
position
before
installing
brake
pads
Page
46-6
Replace
when
replacing
pads
24 - Wheel
bearing
housing
Front brakes, servicing Page 10 / 38
46-6
Removing
CAUTION!
46-7
Installing
WARNING!
CAUTION!
46-8
Note:
46-9
Removing
CAUTION!
Installing
CAUTION!
46-10
WARNING!
46-11
Front brakes,
servicing (Girlin
caliper)
WARNING!
Do not re-use
fasteners that a
worn or
deformed in
normal use.
Some fasteners
are designed to
be used only
once, and are
unreliable and
may fail if reuse
This includes, b
is not limited to,
nuts, bolts,
washers, circlips
and cotter pins.
Always follow
recommendation
in this manual-
replace these
fasteners with
new parts where
indicated, and
any other time it
is deemed
necessary by
inspection.
CAUTION!
After installing
brake pads, depre
the brake pedal
firmly several time
to seat the pads in
their normal
operating position
Note:
46-12
1 - Screw
2 - Brake
pads
With
wear
pad
indicator
Always
replace
both
pairs at
the
same
time
Removing
and
installing
Page
46-15
Thickness:
14 mm
(0.551 in.)
Wear
limit: 7
mm
(0.276
in.)
including
backing
plate
3 - Brake
disc
Removing:
first
remove
brake
caliper
Ventilated
brake
disc (with
4-cyl.
engine):
Front brakes, servicing Page 18 / 38
Diameter:
256 mm
(10.08
in.)
Thickness:
20 mm
(0.787 in.)
Wear
limit:
18
mm
(0.709
in.)
Ventilated
brake
disc (with
VR6
engine):
Diameter:
280 mm
(11.02
in.)
Thickness:
22 mm
(0.866 in.)
Wear
limit:
20
mm
(0.787
in.)
4 - Screw
5 - Wheel
hub
Pressing
out
Page
40-45
Pressing
in
Page
40-48
Front brakes, servicing Page 19 / 38
46-13
6 - ABS
wheel
speed
sensor
rotor
For
ABS
wheel
speed
sensor
7 - 10 Nm (7
ft lb)
8 - Splash
shield
9 - Wheel
bearing
housing
10 - Brake
carrier
Girling
caliper
shown
Replacement
part comes
assembled
with grease
Use
repair kit
if
protective
caps are
damaged
Lubricate
guide
bolts
with
grease
supplied
in repair
kit
11 - Heat
deflector
Front brakes, servicing Page 20 / 38
Insert in
piston
12 - Brake
caliper
CAUTION!
Do not
disconnect
the brake
hose from
the caliper
when
replacing
brake pads.
Do not allow
the caliper to
hang by the
brake hose.
The
unsupported
weight can
stretch and
damage the
hose.
Front brakes, servicing Page 21 / 38
46-14
13 - Bracket
14 - Self-
locking
bolt
Always
replace
35 Nm
(26 ft
lb)
15 - 125 Nm
(92 ft lb)
16 Protective
- cap
17 - Guide
pin
18
Connector
-
For
brake
pad
wear
indicator
19 - Bracket
20 - Bracket
21
Connector
-
For
ABS
wheel
speed
sensor
22 - 10 Nm
(7 ft lb)
23 - ABS
wheel
speed
sensor -
G45-/-
G47-
Front brakes, servicing Page 22 / 38
Install
with
lubricating
paste,
Part No.
G 000
650
Front brakes, servicing Page 23 / 38
46-15
Removing
CAUTION!
46-16
Installing
WARNING!
CAUTION!
46-17
Front brakes,
servicing
(Teves/Ate
caliper)
WARNING!
Do not re-use
fasteners that a
worn or
deformed in
normal use.
Some fasteners
are designed to
be used only
once, and are
unreliable and
may fail if used a
second time. Th
includes, but is
not limited to,
nuts, bolts,
washers, circlips
and cotter pins.
Always follow
recommendation
in this manual-
replace these
fasteners with
new parts where
indicated, and
any other time it
is deemed
necessary by
inspection.
CAUTION!
After installing
brake pads, depre
the brake pedal
firmly several time
Front brakes, servicing Page 26 / 38
46-18
Note:
Wheel bolt
tightening
torque: 110
Nm (81 ft lb).
1 - Screw
2 - Brake
disc
Before
removing,
remove
brake
caliper
Ventilated
brake
disc
diameter:
288 mm
(11.34
in.)
Brake
disk
thickness:
25 mm
(0.98 in.)
Wear
limit:
23
mm
(0.90
in.)
3 - Brake
pads
Always
replace
both
pairs at
the
same
time
Pads
Front brakes, servicing Page 28 / 38
are
different,
pad with
retaining
spring to
piston
side
Removing
and
installing
Page
46-22
Pad
thickness:
14 mm
(0.551
in.)
Checking
thickness:
Repair
Manual,
Maintenance
Wear
limit: 7
mm
(0.276
in.)
including
backing
plate
4 - Brake
pad
retaining
spring
Insert in
both
brake
caliper
mounting
holes
Front brakes, servicing Page 29 / 38
46-19
5 - Brake
carrier
Replacement
part comes
assembled
with guide
pins greased
Use
repair kit
if
protective
caps are
damaged
Lubricate
guide
pins with
grease
supplied
in repair
kit
6 - Brake
caliper
Removing
and
installing
Page
46-22
CAUTION!
Do not
disconnect
the brake
hose from
the caliper
when
replacing
brake pads.
Do not allow
the caliper to
hang by the
brake hose.
The
unsupported
Front brakes, servicing Page 30 / 38
weight can
stretch and
damage the
hose.
7 - Guide pin
25 Nm
(18 ft lb)
Removing
and
installing
Page
46-22
8 - Protective
cap
Front brakes, servicing Page 31 / 38
46-20
9 - Seal
Always
replace
To
remove,
lever
out
using
suitable
tool
10 - Brake
hose
11 - Banjo
bolt
30
Nm
(22 ft
lb)
12 - Bolt
125
Nm
(92 ft
lb)
13 - Wheel
bearing
housing
14 - Socket
head
bolt
10
Nm
(89 in.
lb)
15 - ABS
wheel
speed
sensor
-G45-/-
G47-
Only on
vehicles
Front brakes, servicing Page 32 / 38
with
ABS
Before
installing
sensor,
clean
mounting
hole inner
surface
and coat
with
lubricating
paste,
Part No.
G 000
650
16 - Splash
shield
17 - Bolt
10
Nm
(89 in.
lb)
Front brakes, servicing Page 33 / 38
46-21
18 - ABS
wheel
speed
sensor
rotor
Only on
vehicles
with ABS
19 - Wheel hub
Removing
and
installing
Page
40-39
20 Countersunk
- bolt
Front brakes, servicing Page 34 / 38
46-22
Removing
Note:
46-23
CAUTION!
46-24
Installing
WARNING!
CAUTION!
46-25
46-26